Cobramatic (42 Volt) Wire Feed Cabinet Owner’s Manual · Cobramatic® (42 Volt) Wire Feed Cabinet. ... c. Fire And exPlosion Prevention Causes of fire and explosion are: combustibles

Owner’s ManualProduct: CobramaticManual: 091-0498Serial: 01010001Voltage Rating: 42 VACRevision: Dec. 2001 AModel Number: 150-205

Cobramatic® (42 Volt)Wire Feed Cabinet

Cobramatic® Safety - page i

SAFETY CONSIDERATIONSELECTRIC ARC WELDING EQUIPMENT

CAUTION : READ BEFORE ATTEMPTING INSTALLATION, OPERATION OR MAINTENANCE OF THIS EQUIPMENT

1-1 INTRODUCTIONThis equipment is intended for ultimate application by commercial/industrial users and for operation by persons trained and experienced in the use and maintenance of welding equipment. Operation should not be undertaken without adequate training in the use of such equipment. Training is available from many public and private schools or similar facilities.

Safe practices in the installation, operation and maintenance of this equipment requires proper training in the art, a careful study of the information provided with the equipment, and the use of common sense. Rules for safe use are generally provided by suppliers of welding power sources, compressed gas suppliers, and electrode suppliers. Careful compliance with these rules will promote safe use of this equipment.

The following Safety Rules cover some of the more generally found situations. READ THEM CAREFULLY. In case of any doubt, obtain qualified help before proceeding.

1-2 GENERAL PRECAUTIONSA. Burn Prevention

ELECTRIC ARC WELDING PRODUCES HIGH INTENSITY HEAT AND ULTRAVIOLET RADIANT ENERGY WHICH MAY CAUSE SERIOUS AND PERMANENT EYE DAMAGE AND WHICH MAY DAMAGE ANY EXPOSED SKIN AREAS.

Wear helmet with safety goggles or glasses with side shields underneath, appropriate filter lenses or plates (protected by clear cover glass). This is a must for welding or cutting (and chipping) to protect the eyes from radiant energy and flying metal. Replace cover glass when broken, pitted, or spattered.

Medical first aid and eye treatment. First aid facilities and a qualified first aid person should be available for each shift unless medical facilities are close by for immediate treatment of flash burns of the eyes and skin burns.

Wear protective clothing - leather (or asbestos) gauntlet gloves, hat, and high safety-toe shoes. Button shirt collar and pocket flaps, and wear cuffless trousers to avoid entry of sparks and slag.

Avoid oily or greasy clothing. A spark may ignite them.

Flammable hair preparations should not be used by persons intending to weld or cut.

Hot metal such as electrode stubs and work pieces should never be handled without gloves.

Ear plugs should be worn when working on overhead or in a confined space. A hard hat should be worn when others work overhead.

B. toxic Fume Prevention

WARNING: The use of this product may result in exposure to chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

Adequate ventilation. Severe discomfort, illness or death can result from fumes, vapors, heat, or oxygen enrichment or depletion that welding (or cutting) may produce. Prevent them with adequate ventilation. NEVER ventilate with oxygen.

Lead-, cadmium-, zinc-, mercury-, beryllium-bearing and similar materials, when welded or cut, may produce harmful concentrations of toxic fumes. Adequate local exhaust ventilation must be used, or each person in the area, as well as the operator, must wear an air-supplied respirator. For beryllium, both must be used.

Metals coated with or containing materials that emit toxic fumes should not be heated unless coating is removed form the work surface, the area is well ventilated, or the operator wears an air-supplied respirator.

Work in a confined space only while it is being ventilated and, if necessary, while wearing an air-supplied respirator.

Gas leaks in a confined space should be avoided. Leaked gas in large quantities can change oxygen concentration dangerously. Do not bring gas cylinders into a confined space.

Leaving confined space, shut OFF gas supply at source to prevent possible accumulation of gases in the space if downstream valves have been accidentally opened or left open. Check to be sure that the space is safe before reentering it.

Vapors from chlorinated solvents can be decomposed by the heat of the arc (or flame) to form PHOSGENE, a highly toxic gas, and other lung and eye irritating products. The ultraviolet (radiant) energy of the arc can also decompose trichloroethylene and perchloroethylene vapors to form phosgene. DO NOT WELD or cut where solvent vapors can be drawn into the welding or cutting atmosphere or where the radiant energy can penetrate to atmospheres containing even minute amounts of trichloroethylene or perchloroethylene.

c. Fire And exPlosion Prevention

Causes of fire and explosion are: combustibles reached by the arc, flame, flying sparks, hot slag, or heated material, misuse of compressed gases and cylinders, and short circuits.

BE AWARE THAT flying sparks or falling slag can pass through cracks, along pipes, through windows

or doors, and through wall or floor openings, out of sight of the goggled operator. Sparks can fly many feet.

To prevent fires and explosion:

Keep equipment clean and operable, free of oil, grease, and (in electrical parts) of metallic particles that can cause short circuits.

If combustibles are in area, do NOT weld or cut. Move the work if practicable, to an area free of combustibles. Avoid paint spray rooms, dip tanks, storage areas, ventilators. If the work cannot be moved, move combustibles at least 35 feet away, out of reach of sparks and heat; or protect against ignition with suitable and snug-fitting, fire-resistant covers or shields.

Walls touching combustibles on opposite sides should not be welded on (or cut). Walls, ceilings, and floor near work should be protected by heat-resistant covers or shields.

Fire watcher must be standing by with suitable fire extinguishing equipment during and for some time after welding or cutting if:

1. Appreciable combustibles (including building construction) are within 35 feet.

2. Appreciable combustibles are further than 35 feet, but can be ignited by sparks.

3. Openings (concealed or visible) in floors or walls within 35 feet may expose combustibles to sparks.

4. Combustibles adjacent to walls, ceilings, roofs, or metal partitions can be ignited by radiant or conducted heat.

Hot work permit should be obtained before operation to ensure supervisor’s approval that adequate precautions have been taken.

After work is done, check that area is free of sparks, glowing embers, and flames.

An empty container that held combustibles, or that can produce flammable or toxic vapors when heated, must never be welded on or cut, unless container has first been cleaned in accordance with industry standards.

This includes: a thorough steam or caustic cleaning (or a solvent of water washing, depending on the combustible’s solubility), followed by purging and inerting with nitrogen or carbon dioxide, and using protective equipment.

Water-filling just below working level may substitute for inerting.

A container with unknown contents should be cleaned (see paragraph above). Do NOT depend on sense of smell or sight to determine

Cobramatic® Safety - page ii

if it is safe to weld or cut.

Hollow castings or containers must be vented before welding or cutting. They can explode.

Explosive atmospheres. NEVER weld or cut where the air may contain flammable dust, gas, or liquid vapors (such as gasoline).

d. comPressed GAs equiPment

The safe handling of compressed gas equipment is detailed in numerous industry publications. The following general rules cover many of the most common situations.1. Pressure RegulatorsRegulator relief valve is designed to protect only the regulator from overpressure; it is not intended to protect any downstream equipment. Provide such protection with one or more relief devices.

Never connect a regulator to a cylinder containing gas other than that for which the regulator was designed.

Remove faulty regulator from service immediately for repair (first close cylinder valve). The following symptoms indicate a faulty regulator:

Leaks - if gas leaks externally.

Excessive Creep - if delivery pressure continues to rise with downstream valve closed.

Faulty Gauge - if gauge pointer does not move off stop pin when pressurized, nor returns to stop pin after pressure release.

Repair. Do NOT attempt repair. Send faulty regulators for repair to manufacturer’s designated repair center, where special techniques and tools are used by trained personnel.2. CylindersCylinders must be handled carefully to prevent leaks and damage to their walls, valves, or safety devices:

Avoid electrical circuit contact with cylinders including third rails, electrical wires, or welding circuits. They can produced short circuit arcs that may lead to a serious accident. (See 1-3C)

ICC or DOT marking must be on each cylinder. It is an assurance of safety when the cylinder is properly handled.

Identifying gas content. Use only cylinders with name of gas marked on them; do not rely on color to identify gas content. Notify supplier if unmarked. NEVER DEFACE or alter name, number, or other markings on a cylinder. It is illegal and hazardous.

Empties: Keep valves closed, replace caps securely; mark MT; keep them separate from FULLS, and return promptly.

Prohibited use. Never use a cylinder or its contents for other than its intended use, NEVER as a support or roller.

Locate or secure cylinders so they cannot be knocked over.

Passageways and work areas. Keep cylinders clear of areas where they may be stuck.

Transporting cylinders. With a crane, use a secure support such as a platform or cradle. Do NOT lift cylinders off the ground by their valves or caps, or by chains, slings, or magnets.

Do NOT expose cylinders to excessive heat, sparks, slag, and flame, etc. that may cause rupture. Do not allow contents to exceed 55 degrees C (130 degrees F.) Cool with water spray where such exposure exists.

Protect cylinders, particularly valves from bumps, falls, falling objects, and weather. Replace caps securely when moving cylinders.

Stuck valve. Do NOT use a hammer or wrench to open a cylinder valve that cannot be opened by hand. Notify your supplier.

Mixing gases. NEVER try to mix any gases in a cylinder.

NEVER refill any cylinder.

Cylinder fittings should never be modified or exchanged.3. HoseProhibited use. Never use hose other than that designed for the specified gas. A general hose identification rule is: red for fuel gas, green for oxygen, and black for inert gases.

Use ferrules or clamps designed for the hose (not ordinary wire or other substitute) as a binding to connect hoses to fittings.

No copper tubing splices. Use only standard brass fittings to splice hose.

Avoid long runs to prevent kinks and abuse. Suspend hose off ground to keep it from being run over, stepped on, or otherwise damaged.

Coil excess hose to prevent kinks and tangles.

Protect hose from damage by sharp edges, and by sparks, slag, and open flame.

Examine hose regularly for leaks, wear, and loose connections. Immerse pressured hose in water; bubbles indicate leaks

Repair leaky or worn hose by cutting area out and splicing. Do NOT use tape.4. Proper ConnectionsClean cylinder valve outlet of impurities that may clog orifices and damage seats before connecting regulator. Except for hydrogen, crack valve momentarily, pointing outlet away from people and sources of ignition. Wipe with a clean, lintless cloth.

Match regulator to cylinder. Before connecting, check that the regulator label and cylinder marking agree, and that the regulator inlet and cylinder outlet match. NEVER Connect a regulator designed for a particular gas or gases to a cylinder containing any other gas.

Tighten connections. When assembling threaded connections, clean and smooth seats where necessary. Tighten. If connection leaks, disassemble, clean, and retighten, using properly fitting wrench.

Adapters. Use a CGA adapter (available from your supplier) between cylinder and regulator, if one is required. Use two wrenches to tighten adapter marked RIGHT and LEFT HAND threads.

Regulator outlet (or hose) connections may be identified by right hand threads for oxygen and left hand threads (with grooved hex on nut or shank) for fuel gas.5. Pressurizing Steps:Drain regulator of residual gas through suitable vent before opening cylinder (or manifold valve) by turning adjusting screw in (clockwise). Draining prevents excessive compression heat at high pressure seat by allowing seat to open on pressurization. Leave adjusting screw engaged slightly on single-stage regulators.

Stand to side of regulator while opening cylinder valve.

Open cylinder valve slowly so that regulator pressure increases slowly. When gauge is pressurized (gauge reaches regulator maximum) leave cylinder valve in following position: for oxygen and inert gases, open fully to seal stem against possible leak; for fuel gas, open to less than one turn to permit quick emergency shut-off.

Use pressure charts (available from your supplier) for safe and efficient recommended pressure settings on regulators.

Check for leaks on first pressurization and regularly thereafter. Brush with soap solution. Bubbles indicate leaks. Clean off soapy water after test; dried soap is combustible.

e. user resPonsiBilities

Follow all Safety Rules.

Remove leaky or defective equipment from service immediately for repair. Read and follow user manual instructions.

F. leAvinG equiPment unAttended

Close gas supply at source and drain gas.

G. roPe stAGinG-suPPort

Rope staging-support should not be used for welding or cutting operation; rope may burn.

1-3 ARC WELDINGComply with precautions in 1-1, 1-2, and this section. Arc Welding, properly done, is a safe process, but a careless operator invites trouble. The equipment carries high currents at significant voltages. The arc is very bright and hot. Sparks fly, fumes rise, ultraviolet and infrared energy radiates, weldments are hot, and compressed gases may be used. The wise operator avoids unnecessary risks and protects himself and others from accidents.

A. Burn Protection

Comply with precautions in 1-2.

The welding arc is intense and visibly bright. Its radiation can damage eyes, penetrate lightweight clothing, reflect from light-colored surfaces, and burn the skin and eyes. Skin burns resemble acute sunburn; those from gas-shielded arcs are more severe and painful.

Cobramatic® Safety - page iii

DON’T GET BURNED; COMPLY WITH PRECAUTIONS.1. Protective ClothingWear long-sleeve clothing in addition to gloves, hat, and shoes. As necessary, use additional protective clothing such as leather jacket or sleeves, flameproof apron, and fire-resistant leggings. Avoid outer garments of untreated cotton.

Bare skin protection. Wear dark, substantial clothing. Button collar to protect chest and neck, and button pockets to prevent entry of sparks.2. Eye and Head ProtectionProtect eyes from exposure to arc. Eyes may be damaged by radiant energy when exposed to the electric arc, even when not looking in the direction of the arc. Never look at an electric arc without protection.

Welding helmet or shield containing a filter plate shade no. 12 or denser must be used when welding. Place over face before striking arc.

Protect filter plate with a clear cover plate.

Cracked or broken helmet or shield should NOT be worn; radiation can be passed through to cause burns.

Cracked, broken, or loose filter plates must be replaced IMMEDIATELY. Replace clear cover plate when broken, pitted, or spattered.

Flash goggles with side shields MUST be worn under the helmet to give some protection to the eyes should the helmet not be lowered over the face before an arc is struck. Looking at an arc momentarily with unprotected eyes (particularly a high intensity gas-shielded arc) can cause a retinal burn that may leave a permanent dark area in the field of vision.3. Protection of Nearby PersonnelEnclose the welding area. For production welding, a separate room or enclosed bay is best. In open areas, surround the operation with low-reflective, noncombustible screens or panels. Allow for free air circulation, particularly at floor level.

Viewing the weld. Provide face shields for all persons who will be looking directly at the weld.

Others working in area. See that all persons are wearing flash goggles.

Before starting to weld, make sure that screen flaps or bay doors are closed.

B. toxic Fume Prevention

Comply with precautions in 1-2B.

Generator engine exhaust must be vented to the outside air. Carbon monoxide can kill.C. Fire and Explosion PreventionComply with precautions in 1-2C.

Equipment’s rated capacity. Do not overload arc welding equipment. It may overheat cables and cause a fire.

Loose cable connections may overheat or flash

and cause afire.

Never strike an arc on a cylinder or other pressure vessel. It creates a brittle area that can cause a violent rupture or lead to such a rupture later under rough handling.

d. comPressed GAs equiPment

Comply with precautions in 1-2D.

e. shock Prevention

Exposed electrically hot conductors or other bare metal in the welding circuit, or in ungrounded, electrically-HOT

equipment can fatally shock a person whose body becomes a conductor. DO NOT STAND, SIT, LIE, LEAN ON, OR TOUCH a wet surface when welding without suitable protection.

To protect against shock:

Keep body and clothing dry. Never work in damp area without adequate insulation against electrical shock. Stay on a dry duckboard, or rubber mat when dampness or sweat cannot be avoided. Sweat, sea water, or moisture between body and an electrically HOT part - or grounded metal - reduces the body surface electrical resistance, enabling dangerous and possibly lethal currents to flow through the body.1. Grounding the EquipmentWhen installing, connect the frames of each unit such as welding power source, control, work table, and water circulator to the building ground. Conductors must be adequate to carry ground currents safely. Equipment made electrically HOT by stray currents may shock, possibly fatally. Do NOT GROUND to electrical conduit, or to a pipe carrying ANY gas or a flammable liquid such as oil or fuel.

Three-phase connection. Check phase requirement of equipment before installing. If only three-phase power is available, connect single-phase equipment to only two wires of the three-phase line. Do NOT connect the equipment ground lead to the third (live) wire, or the equipment will become electrically HOT - a dangerous condition that can shock, possibly fatally.

Before welding, check ground for continuity. Be sure conductors are touching bare metal of equipment frames at connections.

If a line cord with a ground lead is provided with the equipment for connection to a switch box, connect the ground lead to the grounded switch box. If a three-prong plug is added for connection to a grounded mating receptacle, the ground lead must be connected to the ground prong only. If the line cord comes with a three-prong plug, connect to a grounded mating receptacle. Never remove the ground prong from a plug, or use a plug with a broken ground prong.2. ConnectorsFully insulated lock-type connectors should be used to join welding cable lengths.3. CablesFrequently inspect cables for wear, cracks, and damage. IMMEDIATELY REPLACE those with excessively worn or damaged insulation to avoid possibly lethal shock from bared cable. Cables

with damaged areas may be taped to give resistance equivalent to original cable.

Keep cable dry, free of oil and grease, and protected from hot metal and sparks.4. Terminals and Other Exposed PartsTerminals and other exposed parts of electrical units should have insulating covers secured before operation.5. Electrode WireElectrode wire becomes electrically HOT when the power switch of gas metal-arc welding equipment is ON and welding gun trigger is pressed. Keep hands and body clear of wire and other HOT parts.6. Safety DevicesSafety devices such as interlocks and circuit breakers should not be disconnected or shunted out.

Before installation, inspection, or service of equipment, shut OFF all power, and remove line fuses (or lock or red-tag switches) to prevent accidental turning ON of power. Disconnect all cables from welding power source, and pull all 115 volts line-cord plugs.

Do not open power circuit or change polarity while welding. If, in an emergency, it must be disconnected, guard against shock burns or flash from switch arcing.

Leaving equipment unattended. Always shut OFF, and disconnect all power to equipment.

Power disconnect switch must be available near the welding power source.

Cobramatic® Owner’s Manual - page iv

Thank You For selecting a quality product. We want you to takepride in operating this product...as much pride as wehave in bringing the product to you!

When this equipment is shipped, title passes to the purchaser upon receipt by thecarrier. Consequently, claims for material damaged in shipment must be made by thepurchaser against the transportation company at the time the shipment is received.

Please record your equipment identification information below for future reference. Thisinformation can be found on your machine nameplate.

Model Name & Number _____________________

Code & Serial Number _____________________

Date of Purchase _____________________

Whenever you request replacements parts for, or information on this equipment alwayssupply the information you have recorded above.

Please Examine Carton and Equipment For Damage Immediately

Read this Owner’s Manual completely before attempting to use this equipment. Save this manualand keep it handy for quick reference. Pay particular attention to the safety instructions wehave provided for your protection.

Cobramatic® Owner’s Manual - page 1

Table of Contents

Saftey Guidelines..............................................................................i

Installation .........................................................................Section A

Technical Specifications .......................................................................3Machine Grounding .............................................................................3Machine Location ................................................................................3 Input Power Connections .....................................................................3Wire Threading Procedure ...................................................................4Welding Torch Connections ..................................................................5

Operation............................................................................Section B

General Description .............................................................................5Recommended Processes and Equiment ...............................................5Controls and Settings ..........................................................................6POSA Start Operating Procedure...........................................................6

Accessories .........................................................................Section C

Optional Kits .......................................................................................7

Maintenance .......................................................................Section D

Routine Maintenance ...........................................................................8Testing the Feeder...............................................................................8Testing the Torch ................................................................................9

Troubleshooting .................................................................Section E

Troubleshooting Guide .......................................................................10

Diagrams/Parts List .......................................................... Section F

Main PC Boards .................................................................................12Mechanical .......................................................................................13Electrical ...........................................................................................21

Warranty Repair Stations

Safety Warnings

Warranty


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Section A InstallationTechnical SpecificationsWire Diameter Capacity ............................... .030 inch - 1/16 inch ALL Types

Wire Spool Capacity ...................................12 inch Standard

.......................................................................(Insulated or Non-Insulated)

Power Input .................................................42 VAC 50/60 Hz,

.......................................................................150 Watts Peak (3 amps)

Weight ..........................................................41 pounds

Shipping Weight .........................................46 pounds

For Use with torch prefix number .............14X, 16X, and 21X

Support Equipment RequiredC.V. or C.C. power source of sufficient capacity for your needs.

Regulated gas supply and hoses.

Properly sized power leads from power source to wire feeder and ground.

Coolant RecommendationsCoolant recirculator and hose capable of providing a minimum of 1 quart per minute at 45 p.s.i. when using water cooled torches.

Use a name-brand additive which does not contain reactive sulphur or chlorine and does not react with copper, brass, or aluminum.

Check coolant periodically to remain within limits of the following:

A. Coolant Flow rate - 1 quart per minute at 45 p.s.i. B. Resistivity - 10K ohms/centimeter C. Ph Range - 5.5-8.5 D. Particle Size - .005 inchMK Recommended Coolant Solution:

1 part ethylene glycol 3 parts distilled water 1 teaspoon liquid glycerin

Machine GroundingThe Cobramatic® and GMAW wire feeders are ground to the power source through the input cable. The power source grounding terminal must be properly connected to electrical ground per the power source operating manual.

Mounting LocationThe cabinet should be placed in a location where it can be protected from damage. Lead lengths and accessibility must also be considered when installing the cabinet.

Input Connections(See Cabinet and Torch Hook-Up in the Appendix)42 VACYour Wire Feeder comes factory ready to connect into any standard 42VAC power supply.

The 42VAC is connected to the PC Board on terminal strip J5 #1 (neutral) and #2 (hot) and Ground to the Cabinet chassis. See diagram in the appendix.


Shielding GasIn accordance with the required support equipment, the customer must provide a cylinder of shielding gas, a pressure regulator, a flow control valve, and a hose from the flow control valve to the left bottom-most fitting on the power block.

The end of the hose must have a male connector to fit the female 5/8-18 brass fitting. Use a 11/16” wrench to tighten.

Coolant Supply and Return (if used)Using a recirculator with properly mixed coolant, as previously described, connect the coolant RETURN hose to the left middle fitting on the power block. Connect the coolant SUPPLY hose to the left top-most fitting on the power block.

The coolant hoses must have a male 5/8-18 left-hand thread to connect to the power block fittings. Use an 11/16” wrench to tighten.

Welding PowerThe electrode cable coming from the welding power supply should be affixed with a 1/2” copper ring lug. Using a 9/16” wrench, remove the 3/8” bolt and washer from the bottom of the power block. Use a 9/16” wrench to tighten.

It is recommended to make this connection last, after connecting the gas and coolant hoses. Reference Input Connections figure in the Appendix.

Wire Threading ProcedureWire Spool InstallationRelease latches, and open right side door of cabinet.

Remove spool retainer from spindle hub.

Raise wire retainer bar to latched position.

Install wire spool onto spindle hub so that wire feeds from bottom of spool towards slave motor. Make sure that the hole in the spool aligns with pin on spindle hub. The white dot on the end of the spindle hub will aid in this alignment.

Replace the spool retainer nut.

Lower the wire retainer bar onto the spool.

Wire Spool Drag SettingNOTE:

Standard factory setting of the Spindle Tension Knob is set for All Other Wires.

There are two visible position settings for this Knob, IN - All Other Wires (Fig. 1) and, OUT - .030/.035 Al Only (Fig. 2). The Spindle Tension Knob must be set to match the Wire Size Selector Switch on the Cobramatic® front panel.

Section A (Continued)

IN - All other wiresFigure 1

OUT - .030/.035 Aluminum ONLYFigure 2


To change this setting, it is easier done without the spool of wire on the spindle. Remove the wire spool retainer and re-install it reversed back onto the Spindle Tension Knob (Fig. 3). In the “Tool Mode”, the square shaped end of the retainer fits onto the Knob. Grab the retainer and turn in the COUNTER-CLOCKWISE direction until it stops. The Knob is now set to the OUT position (.030/.035 AL Only).

To reset the Knob back to the factory setting of All Other Wires, use the retainer as described above, and turn in the CLOCKWISE direction until it stops. The Knob is now set to the IN position. Turning the retainer and Knob in this direction may require more effort, since turning CLOCKWISE is working against a spring.

Load wire spool onto spindle according to the previous instructions.

Replace the spool retainer nut.

Lower the wire retainer bar onto the spool.

Threading Procedure Place wire size selector switch on front panel to the correct position for the wire being used.

Loosen end of wire from spool and cut off any kinked or bent portions.

Unreel and straighten out first 6” to 8” of wire.

Raise wire type lever to center position.

Route wire into inlet guide, along drive roll groove, and into wire conduit.

Flip wire type lever to show type of wire being used.

Tighten the torch pressure adjusting knob so the wire will be picked up and fed through the contact tip. Proper tension is achieved when wire does not slip if a small amount of pressure is added to the wire as it exits the tip.

Wire Retainer BarThe design of the patented Cobramatic® Wire Retainer Bar performs two very important and very basic functions of the wire feeder: a) spool drag tension, and b) wire maintenance on the spool.

The spool drag tension is set by lowering the wire retainer bar onto the wire inside of the spool. The spring tension of the wire retainer bar applies enough pressure on the spool so that when the torch trigger is released, engaging the brake pall, the spool does not overrun kicking wire off the spool.

Wire maintenance on the spool is performed by the applied pressure of the wire retainer bar spread across the coiled wire on the spool. The replaceable pad (P/N 437-0255) of the wire retainer bar is designed to hold the wire on the spool, maintaining the smooth layering of the wire and keeping it from jumping off, and possibly, electrically shorting to the cabinet chassis.

Section A (Continued)

Wire Spool Retainer In "Tool Mode"; used to change spindle drag.

Figure 3


Welding Torch ConnectionsWork CableConnect a work lead of sufficient size and length (see table below) between the proper output stud on the power source and the work. Be sure the connection to the work makes tight metal to metal electrical contact. Poor work lead connections can result in poor arc initiation, poor weld results and activation of the ground lead protector.

Work Lead Lengths Current 60% Up to 50ft. 10-100ft. Duty Cycle (15.2m) (15.2-30.4m) 300A 0 (53mm) 0 (67mm) 400A 00 (67mm) 00 (85mm) 500A 00 (67mm) 00 (85mm) 600A 000 (85mm) 000 (107mm)

Control CableThe 7-Pin “W” Clocked connector screws onto the mating receptacle on the front panel of the wire feeder. This provides all electrical signals (motor voltage, potentiometer control & trigger) to and from the feeder to the torch.

Wire Conduit InletFront panel access to attach conduit to front of slave motor assembly.

Power Cable InletFront panel access to attach power cable (air or water) to top of power block.

Gas InletFront panel access to attach gas hose to bottom fitting of power block.

Water Inlet (For Water Cooled Torches)Front panel access to connect the water hose to the middle fitting on the power block.

Section B OperationGeneralThe AC slave motor in the feeder runs at a fast, constant speed, but has very low torque. It is always trying to feed more wire than the torch motor wants, and when the motor gets all it wants, it slows the slave motor preventing a bird’s nest. Because of the low torque produced by the slave motor, a brake system is used to prevent wire overrun rather than tension. The spool drag tension is produced by the patented Wire Retainer Bar mechanism to keep the wire slightly taut. The 24 VDC torch pull motor is controlled by a solid state speed control and a potentiometer located in the torch.

Recommended Processes and EquipmentThe Cobramatic® is recommended for use in the GMAW and FCAW welding applications. It is recommended for use with constant voltage power sources. The Cobramatic® is capable of feeding wires (diameter capacity) ranging from .023” through .045” solid/cored and .030” through 1/16” aluminum.

Controls and SettingsOn/Off SwitchPlacing the switch in the “ON” position energizes the feeder circuitry and the power indicator light.

Wire Size Selector SwitchThe wire size selector switch changes the torque of the slave motor for the wire you are using. When in the .030-.035 aluminum only position, the slave

Section B (Continued)


motor produces approximately 1 1/2 lbs. inches and approximately 4 1/2 lbs. inches when in the all other wires position.

NOTE: Operating the cabinet with the switch in the wrong

position will cause wire feed difficulties.

Posa Start ControlsThe Posa Start Run-in Speed Control, located on the front panel, provides adjustment for slow wire run-in. Once the arc has been established, the wire feed speed is automatically changed from the slow run-in speed to the welding speed set on the torch potentiometer.

Posa Start Operating ProcedureGeneralThe Posa Start Run-in Speed Control, located on the front panel, provides adjustment for slow wire run-in. Once the arc has been established, the wire feed speed is automatically changed from the slow run-in speed to the welding speed set on the torch potentiometer.

The Posa Start feature allows the Cobramatic® to be used in combination with constant current DC welding power sources of open circuit voltage in excess of 55 volts - also, any constant voltage welding power source capable of a minimum of 50 amps.

Note: Reverse polarity MUST be used.

Posa Start ConnectionsAttach the #14 single black lead which extends from the back of the cabinet to the negative terminal of the power supply or work ground. The Posa Start lead is internally connected to the P.C. board on terminal strip J6, terminal 2.

CV Posa Start OperationsAttach Cobramatic® to CV power source according to the installation instruc-tions.

Turn the Cobramatic® to the “ON” position and the Posa Start to the “OFF” position.

Adjust power source to desired voltage for your weld condition.

Depress gun trigger and adjust wire feed speed at gun to match voltage setting. If approximate wire feed is not known, it is better to start with excess wire feed rather than too little, in order to prevent a “burn-back”.

Turn the Posa Start switch to the “ON” position. Press torch trigger and, using Run-in Speed Control, adjust wire feed rate to approximately 10% of welding wire speed set at torch.

Strike an arc, and adjust wire feed rate at gun until correct condition is achieved.

CC Posa Start OperationAttach the Cobramatic® to a CC power source according to the installation instructions.

Insure power supply high frequency switch is in the “OFF” position, and power supply is set to DC reverse polarity.

The power supply contactor should be set to “Remote” or “Tig” and the

Section B (Continued)


amperage control set to “Panel” or “Standard” depending on power supply.

Turn the Cobramatic® power switch to the “ON” position and the Posa Start switch to the “OFF” position.

Adjust power source to desired amperage for your weld condition.

Press gun trigger and adjust wire feed speed at gun to match current setting. If approximate wire feed speed is not known, it is better to start with excess wire feed rather than too little, in order to prevent possible damage to the contact tip.

Turn Posa Start switch to the “ON” position. Press torch trigger and, using Run-in Speed Control, adjust wire feed speed to approximately 10% of weld-ing wire speed set at torch.

Strike an arc; if the wire stubs out, reduce wire feed rate at gun, or increase amperage setting on power source.

NOTE: Because the Posa Start Run-in Speed always remains a percentage of the actual welding wire feed rate, the Posa Start run-in speed

will always slow down or speed up proportional to any adjustment you now make at the gun. Therefore, if you slow down

the welding wire feed speed, you will have to increase the Run-in Speed setting.

Section C OPTIONAL KITSThe following is a list of Optional Kits available for the Cobramatic® Wire Feeder.

A detailed description of each kit is given later in this section.

P/N Description005-0674 Gas Purge/Trigger Latch Kit 005-0675 Water Pressure Kit

005-0674 Gas Purge/Trigger Latch KitThe Gas Purge/Trigger Latch Kit is a dual function kit. The kit includes an easy to install interface control PC board, a 24VAC solenoid for pre and post purge control, a modified valve stem for the welding torch and, a front panel switch for activating the Trigger Latch mechanism.

The gas control times have been preset to 0.5 seconds pre-purge and 1.0 seconds post-purge. This offers an optimum amount of inert gas shielding prior to striking the arc and after the arc has been extinguished.

The Trigger Latch mechanism gives the operator the flexibility of normal trigger operation (pull trigger to weld - release trigger to stop). This also offers the comfort of latched trigger operation (pull trigger once to latch and weld - pull trigger again to unlatch and stop).

005-0675 Water Pressure KitBy monitoring the pressure from the water recirculator, the switch uses the pressure as the key safety element in protecting the torch from overheating

Section C (Continued)

CAUTION:Do Not operate this wire feeder on a power source having a high-frequency

starting circuit before making sure that the high frequency portion of thepower source is turned off.

Failure to take this precaution will cause permanentdamage to the Posa Start circuitry.


while welding. If there is a loss of water pressure, the switch will keep the arc from igniting so no welding takes place without water cooling the torch. The benefit of the water pressure switch far exceeds the minimal cost of its purchase and installation.

This kit, when installed into the wire feeder, is physically adaptable to all makes and models of water recirculators using standard fittings (left-hand threaded).

Section D MaintenanceRoutine MaintenanceMaintenance of the torch will normally consist of a general cleaning of the wire guide system, including tubes, drive rolls, and conduits at regular intervals.

Remove spatter build-up from inside of nozzles with a hardwood stick.

The only parts on the Cobramatic® system that are subject to normal wear are the conduit, contact tips, gas cups, front body liners, wire guides, drive and idler rolls. A supply of these parts should be maintained on hand.

If repairs do become necessary, any part can easily be replaced by qualified maintenance personnel.

Your Cobramatic® is designed to provide years of reliable service. Normal wear and component failure may require occasional service.

The number of units in operation and the importance of minimal “down time” will determine to what extent spare parts should be stocked on hand.

Testing the FeederRelay K2 OperationWhen the torch trigger is pressed, 24VAC is sent to the coil of relay K2. When K2 is energized, AC is sent to the slave motor, spool brake, and the AC contactor. Relay K2 is also responsible for sending 24VAC to the speed control circuit and shorting the torch motor leads together when the trigger is released for the dynamic braking system. K2 also provides the closing contactor signal.

Testing the Input Power CircuitsThe AC circuits are protected by fuse F3. If F3 continually blows, disconnect J4 (Brake Solenoid), J7 (Slave Motor) and J5-3 & 4 - if connected (AC Contactor Out.) from the PC board. Replace fuse and re-trigger system. If fuse does not blow, isolate problem by reconnecting J4, J7 and J5-3 & 4 one at a time until the fuse blows.

Section D (Continued)


Testing the Speed Control

NOTE: The torch should be tested first and the amphenol must be connected to the

Cobramatic® to perform this test.

Place a voltmeter across diode D10 and press torch trigger. A reading of 0 - 24VDC should be observed, as the torch potentiometer varied.

Testing the TorchMotor CheckRemove the amphenol connector from the cabinet.

Using the torch amphenol, check the resistance across pins “A” and “B” (motor leads). The resistance across the motor should be between 5-10 ohms.If an open circuit or short exist, check the motor leads and motor indepen-dently.

Testing the Potentiometer - “W” ClockedUsing the torch amphenol, check the resistance across pin “D” (wiper) and pin “C”. The resistance should vary from 0 - 5K ohms.Check the resistance across pin “D” (wiper) and pin “G”. The resistance should vary from 5K - 0 ohms.

Testing the Micro SwitchUsing the torch amphenol, check for continuity across pins “E” and “F” when the trigger is pressed.

24.0

VDC

+ -

D10


Section E Troubleshooting

GNITOOHSELBUORT GNITOOHSELBUORT GNITOOHSELBUORT GNITOOHSELBUORT GNITOOHSELBUORT

MOTPMYS MOTPMYS MOTPMYS MOTPMYS MOTPMYS ESUAC ESUAC ESUAC ESUAC ESUAC YDEMER YDEMER YDEMER YDEMER YDEMER

redeef,hcrottadeeferiwoNevalson,.e.i,gnitarepoton.dionelosekarbrorotom

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.esufecalperneht


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draob.C.P,3J,2JesooLrotcennoc

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Section F Appendices

Diagrams/Parts List

Main P.C. Board Connections ..............................................13

Cabinet and Torch Hook-Up ................................................14

001-4010 Cobramatic Assembly ..........................................15

003-2109 Cobramatic Front Panel Assembly ........................17

003-2060 Cobramatic Slave Motor Assembly .......................18

003-2063 Cobramatic Power Block Assembly .......................19

003-2146 Cobramatic Spindle Brake Assembly .....................20

071-0387 Cobramatic Block Diagram ..................................21

071-0270 Cobramatic Main P.C. Board.................................22

071-0367 Cobramatic Torch Connections .............................23


Main P.C. Board Connections

J14

J2

J1

J3

J4

J13

FRONT PANEL

FRONT PANEL

BRAKE SOLENOID

J7

J8J5J6

SLAVE MOTOR

TRANSFORMER

42 VAC Contactor Out

42 VAC Contactor Out

Input Power - 42 VAC

Input Power - 42 VAC

Posa Start Welding Ground

Closing Contacts Out

Closing Contacts Out

Chassis Ground


Cabinet and Torch Hook-up

Input Connections Torch Connections

Coolant Supply

Coolant Return

Shielding Gas Welding

PowerGas

Water Return

Power/Water In


001-4010 Cobramatic Assembly


This

pag

e in

tent

iona

lly b

lank


003-2109 Cobramatic Front Panel Assembly

011

5380-153KL

BLY

NDI

2/1NT

BPANS

91

2461-300B

C"

W"P7

NO

CYSSA

81

4410-634B

CRF

LNP

SS

71

2100-104KL

BAI

DNI

1ET

ULFB

ONK

62

4000-543CNU04-4#

KLXH

TUN

51

0500-14323-8/3

XH

TUN

41

3200-103KL

BDEL

GTM

LNP

MOR

G

31

1002-300I

BC

V24RF

LNP

YSSA

BCP

21

1361-300IB

CDB

OTDB

RWP

LB

CYSSA

11

2331-300II

BC

05.8NBR

.oN

.ytQ

.oNtra

Pnoitpircse

D

tsiLstra

P


003-2060 Cobramatic Slave Motor Assembly

52FER

7610-130erudecor

PtseT52

R/A

1500-328dnuop

moC

gniniateR

etitcoL42

R/A

1000-5382xulibo

Mesaer

G32

R/A

3400-328gnikcoldaerhT

etitcoL22

12600-357

nolyNtelnI

eriW

ediuG

121

6020-115llo

Revir

D02

10310-705

raeGtfah

S91

17020-105

lloRreldI

gniraeB

811

6510-10582.

x83.

x578.

gniraeB

711

8110-10513..x

05.x

521.1gnirae

B61

14520-734

gnirpS

eveelS

511

5420-734dlo

Mgnirae

Bpa

C41

12320-734

rotoM

evalS

dloMreldI

mrA

311

1320-734roto

Meval

Sdlo

Meldna

H21

10320-734

dloMroto

Meval

Sgnisuo

H11

12851-5 34

rotoM

evalS

etacoLetal

P01

16751-134

doM

gniwStlo

B9

11120-914

61/1x

8/5D

Op

moC

gnirpS

81

5800-91404.

DDx

23/1p

moC

gnirpS

71

8100-54381-61-5

kcoLtuN

61

6000-3338#

kcoLgnirp

SrehsaW

51

8520-03342-01

x4/1

x4/1rdlh

SrcS

44

9520-823lt

SB/1-1

x23-

Bch

SrcS

32

4200--823lt

SB/3

x23-

Bch

SrcS

21

3112-300V24roto

MeuqroT

yssA

11

6710-300tiudno

Cbon

Kyss

A.o

N.yt

Q.o

NtraP

noitpircseD


003-2063 Cobramatic Power Block Assembly

91R/A

4400-328tnalaeS

daerhTepiP

etitcoL

81R/A

3400-328kcoldaerhT

242etitcoL

71R/A

9200-328tnalaeS

daerhTepiP

xolaoN61

35740-357

HLmeF

81-8/5ot

Mtpn4/1rtpA51

16640-357

meF81-8/5

otela

Mtpn4/1rtpA41

15110-357

meFtpm8/1

otela

Mtpn4/1hsuB

311

4110-357spn8/1

xtpn8/1rtpA21

12110-357

elaM

81-8/5ot

elaMtpn4/1

gtF11

18303-534

rosneStnerruCtekcarB01

12161-134

K2BCrewoPkcolB

91

6600-15361/5Ø

eloHgulP

81

5930-243rosneStnerruCrecapS

72

5000-633ltS

573.x

23-6hP

nPrcS6

12520-333

.tS6#

ni -ratSkLrhs

W5

17770-133

DO578.0x

DI193.0talFrehsa

W4

12000-133

ltS6#talFrehsa

W3

14500-923

8/5x

61-8/3xeHrcS

21

1200-313no-hsuPrevieceR

dutS1

13421-300

tratS-asoProsneSyssA

.oN.ytQ

.oNtraPnoitpircseD

tsiLstraP


003-2146 Cobramatic Spindle Brake Assembly

71R/A

9400-328tnenmreP

gnikcoLdaerhT

611

8100-157kcalBlyniV

GL5.

x5.

paC51

19500-327

ekarBtehctaRksiD

411

5460-734eldnipS

311

5460-734eldnipSrecapS

211

9520-734eldnipS

noisneTbonK

111

8520-734eldnipSloopSreniateR

011

6273-134eldnipSlaripSretpadA

91

6621-134gniR

pU-kcaBetalP

81

5900-91457.

x96.

x58.

pmoCgpS

73

9500-914650.

x734.

x864.

pmoCgpS

61

8100-543tS

81-61/5kcoL

xeHtuN5

13130-133

khT521.

xDI

57.rehtaeLrhsW

41

5900-133TSS

4/3x

23/11tlFrhsW

33

3600-133505.

x553.tlFrhs

W2

33603-033

42-0136.

x52.

doMrdlhSrcS1

19312-300

eldnipSgniraeB

yssA.oN

.ytQ.oNtraP

noitpircseDtsiL

straP


071-0387 Cobramatic Block Diagram8 8

7 7

6 6

5 5

4 4

3 3

2 2

1 1

DD

CC

BB

AA

A B C D E F G

TO

RC

HM

OT

OR

TO

RC

HP

OT

TO

RC

HT

RI

GG

ER

CW5K

(+)

(-)

AM

PH

EN

OL

C

ON

NE

CT

OR

MS

"

W"

00

3-

16

42

FR

ON

T

PA

NE

L

J2

J1

J3

W CCW

CW

JUM

PER

CABL

E00

3 13

07

SL

AV

E

MO

TO

R

CO

BR

AM

AT

IC

I

MA

IN

B

OA

RD

RE

VP

/Z

ON

ED

ES

CR

IP

TI

ON

/

D

CN

RELA

Y K2

(AT

POW

ER B

LOCK

)

POSA

STA

RT (S

OU

RCE)

POSA

STA

RT (R

ETU

RN)

TORC

H P

OT

CW

TORC

H P

OT

WIP

ER

TORC

H P

OT

CCW

TORC

H M

OTO

R (+

)

TORC

H M

OTO

R (-)

POW

ER IN

DIC

ATO

R LE

D (H

)

POW

ER IN

DIC

ATO

R LE

D (N

)

1 1

J7-3

WEL

D V

OLT

RED

A B C D E F G

J5

J6

A B C D E F G

J2

J7

J4

J8

J1

J1

4J

13

TORC

H T

RIG

GER

27V

(SRC

)

TORC

H T

RIG

GER

27V

(RTN

)

J3 J4

CO

BR

AM

AT

IC

I

TO

RC

H

"W

"

CL

K

MA

IN S

WIT

CH A

C O

UT

(H),

ORN

TORQ

UE

SWIT

CH (R

ETU

RN),

GRN

TORQ

UE

SWIT

CH (S

OU

RCE)

, BLU

CA

BL

E

00

3-

16

31

12

34

12

34

27VA

C (C

OM

) RED

27VA

C (H

OT)

RED

J1

2

BR

AK

E

SO

LE

NO

ID

TR

AN

SF

OR

ME

R

WE

LD

IN

G

CU

RR

EN

T

DE

TE

CT

OR

P/

N

00

3-

12

43

CA

BL

E

00

3-

13

32

RELA

Y CL

IPP/

N 1

57-0

023

P/N

157

-002

2

-PR

N 3

231

DA

TE

AP

PR

NO

TE

:IF

AN

AC

VOLT

AG

E CO

NTA

CTO

R SI

GN

AL

IS R

EQU

IRED

- M

OVE

WIR

E FR

OM

J6-4

TO

J5-4

- MO

VE W

IRE

FRO

M J6

-3 T

O J5

-3

THIS

DO

CUM

ENT

IS T

HE

PRO

PERT

Y O

F M

K PR

OD

UCT

S IN

C.

IT M

AY

NO

T BE

CO

PIED

, REP

RIN

TED

OR

DIS

CLO

SED

TO

A T

HIR

D

PART

Y, E

ITH

ER W

HO

LLY

OR

IN P

ART

, OR

USE

D A

S A

BA

SIS

FOR

MA

NU

FACT

URE

WIT

HO

UT

THE

PRIO

R W

RITT

EN C

ON

SEN

T O

F

MK

PRO

DU

CTS

INC.

MA

IN S

WIT

CH A

C IN

(N),

YEL

MA

IN S

WIT

CH A

C O

UT

(N),

RED

MA

IN S

WIT

CH A

C IN

(N),

BRN

1 1

P/

N

00

3-

20

60

(

42

V)

P/

N

00

3-

20

78

(

11

5V

)

P/

N

00

3-

20

96

(

11

5V

)P

/N

0

03

-2

09

5

(4

2V

)

P/

N

00

3-

07

73

(

11

5V

)P

/N

0

03

-1

72

3

(4

2V

)

P/

N

00

3-

16

28

(

11

5V

)P

/N

0

03

-1

72

1

(4

2V

)

SC

H

07

1-

02

70

P/

N

00

3-

20

24

(

11

5V

)P

/N

0

03

-2

00

1

(4

2V

)

SC

H

07

1-

03

67

(

42

V)

SC

H

07

1-

03

70

(

11

5V

)

EX

T

CA

P

(4

2V

O

NL

Y)

P/

N

00

3-

17

98

WO

RK

G

RO

UN

D

(B

LK

)

WH

IT

E

BL

AC

K

NE

UT

RA

L

-

WH

IT

E

HO

T

-

BL

AC

K

NE

UT

RA

L

-

WH

IT

E

HO

T

-

BL

AC

K

PO

SA

S

TA

RT

CO

NN

EC

TI

ON

S

CL

OS

IN

G

AC

L

IN

E

IN

AC

V

OL

TA

GE

CO

NT

AC

TO

R

CO

NT

AC

TO

R

11

1

TO P

OW

ER B

LO

CK

1

11

1 1

1

SA

FE

TY

W

IR

EG

RE

EN

AC

(HO

T) B

LACK

AC

(CO

M) B

LACK

J4-1

AC

(H)

J4-2

AC

(N)

J7-1

AC

(H) R

ED

J7-2

AC

(H) B

LK

J7-4

AC

(N) W

HT

J7-6

AC

(N) B

LU

12/0

0

071-

0387

-CO

BRAM

ATIC

I -

11

5V /

42V

BL

OCK

DIAG

RAM

M. K

. PR

ODUC

TS I

NC.

C

11

Thur

sday

, No

vemb

er 3

0, 2

000

Titl

e

Size

Docu

ment

Num

ber

Rev

Date

:Sh

eet

of

1 2 3 4 5 61 21 2 3 4 5 6

123

123

12

1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8

1 2

F14A

27VA

C

F2AC

IN

F3AC

IN

(+)


071-0270 Cobramatic Main PC Board


071-0367 Cobramatic Torch Connections8 8

7 7

6 6

5 5

4 4

3 3

2 2

1 1

DD

CC

BB

AA

A B C D E F G

TORC

H "W

" CL

OCK

NEXT

ASS

EMBL

YUS

ED O

N

REV.

P/ZO

NEDE

SCRI

PTIO

N/DC

N #

DATE

APPR

V.

FOR

0.03

0 -

0.03

5

FOR

ALL

OTHE

R

PRN

28

15-

TORQ

UETO

RQUE

POSA

ST

ART

POSA

ST

ART

TORC

H PO

T CW

TORC

H PO

T W

IPER

TORC

H PO

T C

CW

TORC

H TR

IGGE

R 2

7VAC

(H)

TORC

H TR

IGGE

R 2

7VAC

(H)

TORC

H M

OTO

R (+

)

TORC

H M

OTO

R (-)

POW

ER IN

DIC

ATO

R LE

D (H

)PO

WER

IND

ICAT

OR

LED

(N)

3/9

7

CW

ETS

AD

CN 1

102

39/

97

CKT

42VA

C (N

)42

VAC

(N)

42VA

C (H

)42

VAC

(H)

DCN

12

472

B12

/00

DT

(+)

(-)

MOTO

RTO

RCH

TORC

HPO

T

TORC

HTR

IGGE

R

A B C D E F G A B C D E F G

REVI

SION

S

071

- 03

67B

COBRA

-I 4

2V F

RONT

PAN

EL

M.K.

PRO

DUCT

S16

882

ARMS

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MK Warranty Repair StationsALABAMAAIRGAS – SOUTH, INC.Birmingham, AL205/251-6835

INDUSTRIAL WELDING SERVICESQuinton, AL205/674-3258

WELDING ENGINEERING SUPPLY CO.Prichard, AL334/457-8681

WELDING MACHINE HOSPITALMontgomery, AL334/832-9353

ARIZONAALLSTATE ELECTRIC MOTOR CO.Phoenix, AZ602/233-0500

PRAXAIR DISTRIBUTION, INC.Phoenix, AZ602/269-2151

ARKANSASAPPLIED SERVICES, INC.Benton, AR501/860-6464

ARKANSAS WELDING IND’L SUPPLYHot Springs, AR501/321-9922

CALIFORNIAADVANCED WELDER REPAIRCommerce, CA323/263-7383

AIRGAS – WEST, INC.Gardena, CA310/523-9355

ALL PHASE WELDER REPAIR & CONSULTINGSacramento, CA916/331-0595

ARC PRODUCTS San Diego, CA619/628-1022

CAL-WELD SUPPLY Fresno, CA209/445-0131

EMCO EASTConcord, CA925/798-4411

FRESNO OXYGENFresno, CA559/233-6684

INDUSTRIAL WELDER REPAIRLaPuente, CA626/961-7643

PRAXAIR DISTRIBUTION (ArcRent Div)Long Beach, CA562/427-0099

PRAXAIR DISTRIBUTION, INC.Bakersfield, CA661/327-5336

R. J. KATESSan Diego, CA619/565-6960

RED-D-ARC, INC. Carson, CA310/233-3327

SOUTHWEST WELDER REPAIRFontana, CA909/357-1661

SWEINHART ELECTRIC CO., INC.Long Beach, CA714/521-9100

COLORADOAIRGAS-INTERMOUNTAIN, INC.Colorado Springs, CO719/473-1947

WELDERS & EQUIP. SVC. & TESTINGLittleton, CO303/932-8755

WESTERN SLOPE WELDER REPAIRGrand Junction, CO970/243-9616

FLORIDAA & I SPECIALTIESLehigh Acres, FL941/368-7435

ACTION WELDING SUPPLYJacksonville, FL904/786-2254

AMVEL CORPORATIONMiami, FL305/592-5678

ELECTRICAL WELDERS SERVICEOrlando, FL407/999-5214

HAUN SYSTEMS REPAIR, INC.Orlando, FL407/681-6064


J.K. CIRCUIT TECHNOLOGYBoynton Beach, FL561/733-7859

ROPER ELECTRIC MOTOR SERVICEPanama City, FL 32405850/769-6643

SMITTY’S WELDER SERVICEWest Palm Beach, FL561/845-1224

TRI-GASMiami, FL 305/592-3180

TRI-STATE SALES & LEASINGLake City, FL904/397-3340

GEORGIAB&W INDUSTRIAL SERVICESAugusta, GA706/738-8722

MC CULLOUGH ELEC. MOTOR SVC.Atlanta, GA404/688-5251

HAWAIIDC ELECTRIC, INC. Aiea, HI808/483-8900

IDAHONORCOBoise, ID208/336-1643

ILLINOISINDUSTRIAL WELDER REBUILDERSAlsip, IL708/371-5688

RELIABLE EQUIPMENT REPAIRHamel, IL618/633-5000

SCHERER INDUSTRIAL GROUP, INC.Galesburg, IL309/342-4125 or 888/964-3526

INDIANAAGA GAS, INC.Hammond, IN219/989-9030

AIRGAS – MID AMERICA, INC.Evansville, IN800/371-5688

COX EQUIPMENT CO.Indianapolis, IN317/241-8881

EVANSVILLE ARMATURE, INC.Evansville, IN812/428-9034

MODERN SUPPLY CO., INC.Evansville, IN812/425-9353

PRAXAIR DISTRIBUTION, INC.Speedway, IN317/481-4550

SUTTON-GARTEN COMPANY Indianapolis, IN317/264-3236

IOWAAIRGAS NORTH CENTRALDes Moines, IA515/266-1111

CEDAR RAPIDS WELDING SUPPLYCedar Rapids, IA319/365-1466

ELECTRICAL ENGINEERING & EQUIPMENTDes Moines, IA515/266-8890

WRIGHT WELDING SUPPLY Ft. Dodge, IA515/576-0640

KANSASKANOXHutchinson, KS316/665-5551

KENTUCKYGENERAL WELDING PRODUCTSLouisville, KY502/635-5218

RED-D-ARCLexington, KY800/245-3660

WELDING EQUIPMENTLouisville, KY502/636-0545

LOUISIANARED BALL OXYGEN CO.Shreveport, LA318/425-3211

MICHIGANANN ARBOR WELDING SUPPLY CO.Ypsilanti, MI734/572-0444

APEX WELDING GASES & SUPPLYMuskegon Heights, MI616/722-3185


AUTOMATIC WELDMidland, MI517/496-9245

GREAT LAKES EQUIPMENT Clare, MI517/386-4630

HAMILTON ELECTRIC CO.Saginaw, MI517/799-6291

SAGINAW WELDING SUPPLY CO. (FLINT WELDING SUPPLY CO.-Parent Co.)Saginaw, MI517/793-9696

SOUTH PARK WELDINGMarysville, MI810/364-6521

WELDING METALS, INC.Madison Heights, MI248/585-0480

WESAR COMPANYThree Rivers, MI616/483-9125

MINNESOTAMINNEAPOLIS OXYGEN CO.Minneapolis, MN612/588-8855

OXYGEN SERVICE CO.St. Paul, MN 612/644-7273

MISSOURICEE-KAY SUPPLY, INC.St. Louis, MO324/644-3500

P.G. WALKERSpringfield, MO417/862-1745

MISSISSIPPINORDAN SMITH WELDING SUPPLYHattiesburg, MS601/545-1800

3D SUPPLIES, INC.Jackson, MS601/353-3330

NEVADASIERRA WELDING SUPPLY CO.Sparks, NV775/359-0542

NEW JERSEYINDUSTRIAL ELECTRIC SERVICE CO.Hawthorne, NJ973/423-1212

NEW YORKHAUN WELDING SUPPLYSyracuse, NY 315/463-5241

NORTH CAROLINAHOLOXColfax, NC336/996-1974

M & L WELDER REPAIRAsheville, NC828/250-9353

MACHINE AND WELDING SUPPLY CO.Dunn, NC910/892-4016

MACHINE AND WELDING SUPPLY CO.Greenville, NC252/752-3089

MACHINE AND WELDING SUPPLY CO.Raleigh, NC919/772-9500

MACHINE AND WELDING SUPPLY CO.Winston-Salem, NC336/723-9651

NATIONAL WELDERS SUPPLY CO.High Point, NC910/882-1110

NATIONAL WELDERS SUPPLY CO.Charlotte, NC704/392-7317

OHIOAGA GASSES, INC.Lima, OH419/228-2828

ALBRIGHT WELDING SUPPLYWooster, OH330/264-2021

ARC EQUIPMENT COMPANYStruthers, OH 333/750-9353

ARC SERVICES, INC.Toledo, OH419/478-6204

BELAIR PRODUCTS, INC.Akron, OH330/253-3116

BIG RIVER ELECTRIC Gallipolis, OH740/446-4360


CnD MACHINE, INC.Canton, OH 44706330/478-8811

RICK’S WELDER REPAIR SERVICEEastlake, OH440/269-1204

VALLEY NATIONAL GASESHilliard, OH614/771-1311

VALLEY NATIONAL GASESLima, OH419/228-1008

VALLEY NATIONAL GASESToledo, OH419/241-9114

WEILER WELDING CO., INC.Dayton, OH 937/222-8312

WELDINGHOUSE, INC.Cleveland, OH216/524-1955

VOLLMER ELECTRIC CO.Columbus, OH614/476-8800

WEILER WELDING CO., INC.Dayton, OH 937/222-8312

WELDINGHOUSE, INC.Cleveland, OH216/524-1955

OKLAHOMAAIRGAS MID-SOUTH Tulsa, OK918/582-0885

BILL’S WELDER REPAIROklahoma City, OK405/232-4799

MUNN SUPPLYEnid, OK580/234-4120

OKLAHOMA WELDERS SUPPLYMadill, OK580/795-5561

OREGONIndustrial Source, Inc.Eugene, OR541/344-1438

PENNSYLVANIAALLWELD EQUIPMENT REPAIRPittsburgh, PA412/821-8460

GEOVIC WELDING SUPPLYMilton, PA717/742-9377

J.A. CUNNINGHAM EQUIPMENT, INC.Philadelphia, PA215/426-6650

POWER SOURCE REPAIR CO., INC.Collingdale, PA610/532-6460

VALLEY NATIONAL GASESPittsburgh, PA412/281-1835

TENNESSEENEXAIRMemphis, TN901/523-6821

TRAMCOBristol, TN423/968-4499

NATIONAL RENTRAL & REPAIRKnoxville, TN423/584-6390

TEXASAIRGAS SOUTHWESTHouston, TX713/462-8027

ARC CONTROLHouston, TX713/941-4701

DENISON OXYGENDenison, TX903/465-3369

FT. WORTH WELDERS SUPPLY, INC. Ft. Worth, TX 817/332-8696

RITE-WELD SUPPLY, INCFort Worth, TX817/626-8237

UTAHC.W. SILVER INDUSTRIAL SERVICESalt Lake City, UT801/531-8888

VIRGINIAAIR PRODUCTS & CHEMICALSBristol, VA540/669-3161


ARC WELDERS, INC.Ashland, VA804/798-1818

NORFOLK WELDERS SUPPLYNorfolk, VA804/622-6571

WASHINGTONAIRGAS – NORPAC, INC.Tacoma, WA253/473-2282

A-L WELDING PRODUCTSTukwila, WA425/228-2218

AMERICAN EQUIPMENT SERVICESKent, WA253/395-9947

HARRIS ELECTRIC, INC. Seattle, WA206/782-6668

OXARC, INCSpokane, WA509/535-7794

PACIFIC WELDING SUPPLIESTacoma, WA253/572-5302

PRECISION WELDER AND ENGINE REPAIRSeattle, WA206/382-6227

WEST VIRGINIACARDINAL SALES & SERVICE, INC.Clarksburg, WV304/622-7590

WISCONSININTERSTATE WELDING SALES CORP.Appleton, WI920/734-7173

PRAXAIR DISTRIBUTION, INC.Brookfield, WI414/938-6365

CANADAA & A WELDER SERVICES LTD.Saskatoon, Saskatchewan306/934-1601

ARC & GENERATOR REPAIRGarson, Ontario705/525-2141

BARRY HAMEL EQUIPMENT LTD.Coquitlam, B.C.604/945-9313

ELECTRO-MÉCANIK, INC.Sainte-Foy, Quebec418/683-1724

GPR INDUSTRIES 1994 LTD.Grande Prairie, Alberta780/532-5900

HYPERDYNAMICS TECHNOLOGIES LTD.Pickering, Ontario905/683-9938

INDUSTRIAL ELECTRONIC SERVICESCalgary, Alberta403/279-3432

LADEL Ltd.Quebec, Canada819/376-6577

M.R.T. REPAIR CENTER, INC.Montreal, Quebec514/648-0800

OZARK ELECTRICAL MARINE LTD.St. John’s Newfoundland709/726-4554

PEEL ENGINESMississauga, Ontario905/670-1535

PROMOTECH ÉLECTRIQUE, Inc.Fleurimont, Québec819/822-2111

WELDERS SUPPLYWinnipeg, Manitoba204/772-9476

WELDING WIDE SERVICES, INC.Brampton, Ontario905/874-9992

WELDTECB.C., Canada604/545-3886

CHINAPHT GROUP COMPANYBeijing, China




DATE : March 1, 2001

LIMITED WARRANTY - MK Products,Inc.,Irvine,California warrants that all new and unused equipment furnished by MK Products is free from defect in workmanship and material as of the time and place of delivery by MK Products. No warranty is made by MK Products with respect to trade accessories or other items manufactured by others. Such trade accessories and other items are sold subject to the warranties of their respective manufacturers, if any.

MK Products’ warranty does not apply to components having normal useful life of less than one (1) year, such as relay points, wire conduit, tungsten, and welding torch parts that come in contact with the welding wire, including gas cups, gas cup insulators, and contact tips where failure does not result from defect in workmanship or material.

In the case of MK Products’ breach of warranty or any other duty with respect to the quality of any goods, the exclusive remedies therefore shall be at MK Products’ option:

(1) repair(2) replacement(3) where authorized in writing by MK Products, the reasonable cost of repair or replacement at our Irvine, California plant; or(4) payment of or credit for the purchase price (less reasonable depreciation based upon actual use) upon return of the goods at customer’s risk and expense. Upon receipt of notice of apparent defect or failure, MK Products shall instruct the claimant on the warranty claim procedures to be followed.

As a matter of general policy only, MK Products may honor an original user’s warranty claims on warranted equipment in the event of failure resulting from a defect within the following periods from the date of delivery of equipment to the original user:

1. Torches,Weldheads,andWaterRecirculators.................... 1year2. AllOtherEquipment............................................................. 3years3. Repairs..................................................................................90days

Classification of any item into the foregoing categories shall be at the sole discretion of MK Products. Notification of any failure must be made in writing within 30 days of such failure.

A copy of the invoice showing the date of sale must accompany products returned for warranty repair or replacement.

All equipment returned to MK Products for service must be properly packaged to guard against damage from shipping. MK Products will not be responsible for any damages resulting from shipping.

Normal surface transportation charges (both ways) for products returned for warranty repair or replacement will be borne by MK Products, except for products sold to foreign markets.

ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY, GUARANTY, OR REPRESENTA-TION AS TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF CONTRACT WHICH, BUT FOR THIS PROVI-SION, MIGHT ARISE BY IMPLICATION, OPERATION OF LAW, CUSTOM OF TRADE, OR COURSE OF DEALING, INCLUD-ING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MK PRODUCTS, IS EXCLUDED AND DISCLAIMED BY MK PRODUCTS.

EXCEPT AS EXPRESSLY PROVIDED BY MK PRODUCTS IN WRITING, MK PRODUCTS ARE INTENDED FOR ULTIMATE PURCHASE BY COMMERCIAL/INDUSTRIAL USERS AND FOR OPERATION BY PERSONS TRAINED AND EXPERI-ENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT AND NOT FOR CONSUMERS OR CONSUMER USE. MK PRODUCTS WARRANTIES DO NOT EXTEND TO, AND NO RE-SELLER IS AUTHORIZED TO EXTEND MK PRODUCTS’ WARRANTIES TO ANY CONSUMER.

16882 Armstrong Ave.Irvine, CA 92606Tel (949)863-1234Fax (949)474-1428www.mkproducts.com

Effective March 1, 2001This warranty supersedes all previous MK Products warranties and is

exclusive, with no other guarantees or warranties expressed or implied.

16882 Armstrong Ave.Irvine, California 92606

Tel 949.863.1234Fax 949.474.1428

[email protected]

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